Metal Roofi ng & Cladding

G U I D E

P R E - P A I N T E D

insideIntroduction 3

Product Overview 4

Huge range of Possibilities 7

Colours 7

Refl ectivity 7

Atmospheric Environments 8

Warranty 10

Design & Installation Fundamentals 12

Design Issues 13

Basic Chemistry and the Properties of Metals 14

Holes, Penetrations, Fixtures, Fittings and Fasteners 16

Maintenance 17

Step by Step Guide forColorCote® roofi ng & cladding 18

Sustainability and recycling 20

Where to go for more information, ideas or help? 21

CONTENTS

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• Get the fundamentals right and avoid

potential pitfalls,

• increase the lifespan of your roofi ng and

cladding,

• save thousands of dollars in repair, maintenance

and replacement costs.

Like many aspects of building or renovating a

home, mistakes with your roofi ng and cladding

can be expensive – not just in fi nancial terms but

in worry, stress and manual labour.

Decisions need to be made on a product’s

suitability for the house design, its suitability for

its geographic or climatic environment, its lifespan

and maintenance requirements -- not just the

initial up front cost. Spending a little bit more now

and getting it right can save you thousands of

dollars and lots of extra work over the life of your

roofi ng or cladding. It is important to remember

too that the cost of your roof is only about 5% of

the total cost of your home.

Your roof and cladding are two of the largest and most obvious visual features of your home.

When you’re building or renovating there are a number of important questions you need to ask to get

the right roof or cladding for your home. You want products that will give you the look and protection

you are after and will stay looking good for years and years.

ColorCote® Pre-Painted Metal Roofi ng & Cladding Guide gives you the knowledge and understanding

you need to have informed discussions on pre-painted metal roofi ng and cladding with architects,

designers, builders and other trades people.

This knowledge will help you:

Introduction

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ColorCote® pre-painted steel and

aluminium roofi ng and cladding

products have been manufactured in

New Zealand for more than 30 years.

To ensure all its colours and coatings

are more than equal to the worst the

New Zealand climate can throw at

them, Pacifi c Coilcoaters runs a rigorous

testing regime, with exposure sites at

Muriwai Beach on the untamed west

coast of the North Island and in the

Auckland industrial suburb of Penrose.

There is a six-tier range of ColorCote®

pre-painted metal roofi ng and cladding

products – AR8™/ARX™, ZM8™,

ZMX™, ZRX™ and ZR8™ – all using the

latest coating technology. They have

either a steel (with a corrosion-resistant

zinc coating) or aluminium substrate

and each product has a different level of

primer and type of top-coat depending

on the environment in which it is to be

used.

There are ColorCote® systems to suit

all New Zealand homes. Which is best

for your home is determined by your

climatic environment or geographic

location.

ColorCote® ZR8™

Suitable for moderate climatic

environments, ZR8™ has a hot-dipped

aluminium/zinc alloy-coated steel

substrate. It has a waterborne or

polyester top coat baked on a polyester

primer, giving an extremely durable

paint system that resists UV damage

and provides excellent gloss and colour

retention.

ColorCote® ZM8™

Suitable for moderate and severe

marine environments, ZM8™ has a

hot-dipped aluminium/zinc/magnesium

alloy-coated steel substrate which gives

it enhanced cut-edge and wet-area

performance. It has a waterborne or

polyester top coat baked on a polyester

primer, giving an extremely durable

paint system that resists UV damage

and provides excellent gloss and colour

retention.

ColorCote® ZMX™

ZMX™ has a hot-dipped aluminium/

zinc/magnesium alloy-coated steel

substrate which gives it enhanced cut-

edge and wet-area performance. It has

a thicker coating of polyester primer

for improved corrosion resistance and

a 70% PVF2 top coat. This system gives

outstanding gloss, colour retention

and durability in severe and industrial

environments.

ColorCote® ZRX™

ZRX™ has a hot-dipped aluminium/

zinc alloy-coated steel substrate with a

thicker coating of polyester primer for

improved corrosion resistance and a

70% PVF2 top coat. This system gives

outstanding gloss, colour retention

and durability in severe and industrial

environments.

AR8™ and ARX™

Using type 5052 or 5005 marine grade

aluminium alloy substrates, polyester

primer, a choice of waterborne,

polyester or 70% PVF2 top coats,

AR8™ and ARX™ are designed for

use in severe and very severe marine

environments and are ideal for cladding.

Product Overview

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Huge Range of PossibilitiesColorCote® pre-painted metal roofi ng and cladding systems provide design fl exibility unmatched

by any other roofi ng or cladding material. ColorCote® can be roll-formed or pressed into a range

of profi les that look great and are warranted to last.

It is easy to install and can be adapted to almost any design or construction concept.

It has the strength to span wide spaces with simple and lightweight support systems and can be

bent or curved to suit an almost unlimited range of innovative designs and roof pitches.

ColoursThe expansive ColorCote® range of colours gives homeowners a great-looking choice whatever

your architectural or design taste.

There are more than 80 colours in the ColorCote® palette – natural, earth and autumn shades,

pastels, bold primary colours, metallics and even black and white. If none of these colours suit,

custom colours can be manufactured on request.

Refl ectivityNew Zealand local authorities and councils are looking to reduce the impact of construction and

buildings on the visual landscape, particularly in rural, coastal and alpine areas.

Councils are wanting new buildings to blend in with the natural environment and are enforcing

refl ectivity levels based on standard ASTM E903-96 which measures the average values for

refl ected solar radiation from building products – the lower the value the less refl ected

light/glare.

That is why ColorCote® has developed its Naturals range of earthy low refl ectivity colours (each

with low refl ectivity, colour and gloss) to fi t in with the New Zealand landscape. The refl ectivity

value for each Naturals colour is listed on the Naturals colour chart.

See www.colorcote.co.nz or your local council website for more details.

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PRODUCT TYPE 2-4 5

SEVERE MARINEISO Category 4

MILDISO Category 1-2

Areas far inland

MODERATEISO Category 2

Inland other thanfar inland

INDUSTRIALISO Category 3-4INDUSTRIAL

ISO Category 3-4

Areas around major industrial complexes

MARINEISO Category 3

Areas influenced by coastal salts

Begins anywhere from 100-400 metres in from the beach front of

breaking surf and can extend inland

Atmospheric EnvironmentsU S A G E G U I D E

www.colorcote.co.nz

Atmospheric EnvironmentsIt is very important to use the correct

ColorCote® pre-painted metal

roofi ng or cladding system for the

appropriate atmospheric environment.

Installing a system designed for

moderate environment in a very severe

environment will mean a shorter product

lifespan, an onerous maintenance

schedule and no protection under Pacifi c

Coilcoaters’ warranty programme.

It is also important to recognise that

manufacturers’ environmental usage

tables are only rough guides to local

climatic and geographical conditions.

Salt-laden sea air does not stop

where the chart says the boundaries

are. Prevailing winds and regional

topographical variations can amplify

the true range of severe marine

environments to many kilometres inland

from the sea.

A simple rule of thumb is that if you

can see the sea from your property an

aluminium substrate (ARX™ or AR8™)

should be used.

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VERY SEVEREISO Category 5

Industrial and Geothermal

Very Severe MarineOffshore and anywhere within

100-400 metres from the water line of areas of breaking surf but can extend inland

If in doubt contact Pacifi c Coilcoaters for

specifi c recommendations.

The design of your house can also

dictate which system should be used. For

example a house with a minimum pitch

roof with parapets two kilometres from

the surf should use ARX™.

The same house with a steeper pitched

roof (which allows rainwater to wash off

the worst of the salt residue) could use

ZR8™ but the cladding should still be

ARX™.

In severe marine environments care

needs to be taken with cut edges and

penetrations --including screw holes

-- to prevent the spread of corrosion

(with aluminium substrates this is not as

critical).

Using the best paint system for the

job and choosing between a steel or

aluminium substrate (depending on the

environment) will add years to the life of

your roof... and save you money too!!

It can be a false economy to buy a

product on cost alone – particularly

something like pre-painted metal

roofi ng and cladding that is protecting

your home from the elements.

Sometimes the initial installed price may

be a little more up front, but over a 30

– 50 year lifespan you’ll come out way

ahead.

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Most roofi ng companies will give you a warranty

for their products.

However, all warranties are not the same. Just because

a company is willing to give you a warranty won’t make

your roof or cladding any more durable or resistant to

the elements.

Some roofi ng companies might be prepared to give you

a 15-year warranty on a basic roofi ng system in a harsh

or marine environment. You might think you’re saving

money but look closely at the fi ne print: somebody’s

going to have to climb up on the roof every month and

scrub it down with a hose and brush.

Who’s going to do that? …You?

Even worse; if you don’t meet the onerous conditions,

and the roof starts to fail after a few years, you’ll have to

replace it at your own cost.

Warranty

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All ColorCote® roofi ng and cladding products come with a

Pacifi c Coilcoaters’ written warranty. Our warranties are specifi c

to a particular building, where it is sited, and the type of

roofi ng and cladding product used. Because we make sure you

use the right product for the job and its environment,

only normal maintenance – usually a wash every six months

– is required. Residential warranty terms and warranty

applications can be accessed by visiting the ColorCote®

website: www.colorcote.co.nz.

To avoid problems later, or for specifi c advice on your proposed

roofi ng or cladding designs, you can email or fax your plans

to Pacifi c Coilcoaters before you start construction. Pacifi c

Coilcoaters will let you know which is the best coating and

substrate solution for the design you want and will also

recommend fi xings based on environmental and design

considerations. This means you’ll get the correct ColorCote®

product for your home and also means the solution provided

will come with a pre-approved warranty.

SeismicBecause of New Zealand’s geographic position on the Pacifi c

rim-of-fi re, our homes have to be designed to resist not

only our weather but also volcanic or earthquake activity.

A ColorCote® roof is strong and secure and also relatively

lightweight. A ColorCote® pre-painted steel roof on the

average 150 sq. metre home weighs less than a tonne.

By contrast, a concrete tile roof on the same house could

weigh more than eight tonnes and would require additional

structural, engineering and labour costs.

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Design & Installation FundamentalsWhen designing your home make sure you

take time to look carefully at your roofi ng or

cladding plans.

Good design and a bit of good old-

fashioned commonsense can save you a lot

of time, effort, aggravation and heartache.

If you see anything in this section that you

think might cause a problem for your home

talk to your architect, builder or roofer

about it.

Or contact Pacifi c Coilcoaters at

www.colorcote.co.nz.

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Design IssuesThe design of your house will affect the life of your

pre-painted roofi ng and cladding. It is best to avoid

overhangs and designs that create unwashed areas.

These are not naturally washed down by rainwater

allowing dirt, salts and other corrosive elements to

build up.

Good design can get rid of most unwashed areas at the

planning stage. You also need to think of how the roof

is going to be maintained. All roofs need to be washed

down on a regular basis so you need to think of how you

are going to access the roof. If the pitch of the roof is too

steep to walk on safely you might have to hire a cherry

picker or crane every time maintenance is required.

Orientation of the roof is important too, particularly in

severe environments. It is important when looking at

the aspect of the roof that the metal profi le is protected

from the effects of salt-laden air being driven in from the

sea under the roof profi le and accelerating corrosion. In

severe and very severe environments it is also important

that the right roof profi le is chosen.

In such exposed environments care should also be taken

when installing spouting. The spouting profi le needs to

be correctly fi xed to prevent corrosive wind-driven water

and salts being driven up under the sheets of roofi ng and

causing possible early product failure.

Spouting, valleys and low pitched roofs also need to have

the correct fall to prevent ponding which can accelerate

potential corrosion.

The underside of all pre-painted metal roofi ng, including

soffi ts, should be enclosed. The underside paint system

is usually only a wash coat which is not designed

for exterior exposure and has only limited corrosion

resistance.

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When different types of metals come into contact

with each other, and particularly when water is

present, chemical reactions take place which result in

the metal higher up the galvanic hierarchy of metals

(i.e. metals more resistant to corrosion) eating away

metals lower down the order. Brass, copper, lead and

stainless steel are higher up the galvanic hierarchy

than the aluminium/zinc-coated steel and aluminium

used as ColorCote® pre-painted metal substrates.

Direct contact between these dissimilar metals will

cause the ColorCote® systems to quickly corrode.

Basic Chemistry and the Properties of Metals

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Water coming from copper and brass pipes or

spouting can cause corrosion to pre-painted metal

roofi ng and cladding too.

The best solution is to make sure there is no direct

contact between dissimilar metals.

If necessary, inert membranes can be used to

isolate two different metals. This is the case when

ColorCote® AR8™ and ARX™ are fi xed using stainless

steel fasteners. A special low carbon washer is used

between the two metals.

Other materials that will cause problems:

• Cement will have a corrosive affect on the paint

systems and must be wiped off immediately

• Tanalised timber and some other timbers such

as cedar can cause galvanic corrosion. In mild

atmospheres seal the timber surface with an inert

membrane at the points of contact. In severe and

very severe conditions the two surfaces must be

fully isolated by a rubber or neoprene gasket.

• Concrete and plaster can cause discolouration to

the paint coating which should be protected by an

inert membrane where they come into contact.

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Holes, Penetrations, Fixtures and FittingsCare needs to be taken every time you make a hole in

your pre-painted metal roofi ng and cladding or fi x or

screw something onto it.

Holes and penetrations can let in moisture and

accelerate corrosion if not sealed or fl ashed properly.

So can fi xtures and fi ttings on your roof such as air

conditioning units, fans, aerials, satellite dishes, and

solar panels. Flues and chimneys need to be designed

to allow fumes and smoke to dissipate. The roof near

these will need to be washed regularly to remove

contaminants.

There are also dissimilar metal issues to be aware of

with fi xtures and fi ttings on roofs. Television aerials

and copper waste pipes from gas water heaters are

just two examples that need to be fully isolated from

pre-painted metal roofi ng.

FastenersIt is important to use the correct fastener to install

your ColorCote® pre-painted roofi ng or cladding

system. The fasteners should be matched to the

expected life of the roof.

For ZR8™ and ZM8™, class 4 coated screws are

recommended and give the best service life.

Galvanised nails with ZR8™ or ZM8™ pre-painted

washers can also be used.

For ZMX™ and ZRX™, class 4 coated screws are

recommended but galvanised nails are not to be

used.

Stainless steel or monel metal fasteners are not to be

used on ZR8™, ZM8™, ZMX™ and ZRX™ systems.

For ARX™ or AR8™ systems, 304 stainless steel or

aluminium screws must be used. Holes should be

drilled oversize to allow for movement and profi led

metal washers used to isolate the different metals.

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MaintenanceAll roofi ng and cladding products require regular

maintenance to keep them looking good, to prolong their

life and to meet the terms of any product warranty.

The best way to reduce the amount of maintenance

required is to pick the right product for the environment.

The extremes of temperature, harsh UV rays and salt-

laden sea air all eventually take their toll on all New

Zealand buildings.

That’s why it’s important you get the correct pre-painted

metal roofi ng and cladding system for your house

whether you’re living in the city, beside the sea or out in

the country.

The harsher the environment the more important it is that

a regular maintenance schedule is followed – particularly

regular washing down of roofs and cladding -- to

maximise service life and appearance.

• All roofi ng and cladding needs to be washed down

with clean water and a soft-bristle brush or sponge

on a regular basis. For larger areas water blasting at

pressures up to 20Mpa might be more appropriate.

How often depends on the pre-painted system and

the severity of the building environment. Give special

attention to unwashed areas and around penetrations

and fi xtures and fi ttings. Pacifi c Coilcoaters

recommends roofi ng or cladding should be washed

down a minimum of every six months, or more often if

contaminants build up.

• If you are not comfortable doing it yourself get a

professional in. It must be done on a regular basis to

meet the terms of your warranty.

• Clean and clear gutters and downpipes regularly too.

• Take sensible safety precautions when climbing on a

roof. Secure your ladder properly, use non-slip shoes

and safety harnesses if necessary, and don’t go up on a

roof in wet, windy or icy conditions.

• Make sure fasteners are also washed and inspected for

signs of corrosion. Replace them immmediately if they

are showing signs of failure or rust.

Basic Maintenance Needs:

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Step by Step

Guide for

ColorCote®

roofi ng

and

cladding

Check with your roof

manufacturer or Pacifi c

Coilcoaters that your

project meets pre-

approved ColorCote®

warranty conditions.

www.colorcote.co.nz

Select a suitable builder

and/or roofi ng and

cladding fi xer.

Talk to your architect or designer about

your ideas. Work with him or her to

get the look you want. Ask any of the

questions above or any others your

research has raised.

Are there any big spans, curves or bends?

Will that impact on which ColorCote® system

you choose? What roofi ng or cladding profi le

is suitable for this design? Do you need to

check with you architect/designer or the roof

manufacturer?

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Colour: How does

the roof colour work

with the overall house

colour scheme? Is it

an expression of your

personality? Will the

colour scheme jar with

its environment? Does

it matter? Are there any

local authority restrictions

on the colours you can

use?

How can you keep

penetrations and aerials

and other fi xtures to a

minimum?

Can you design out any

sheltered or overhanging

areas or other features

that allow the build

up of salts and other

contaminants and which

might affect the long

term performance of the

roofi ng and cladding?

Does the design of the roofi ng or

cladding enhance the overall design

of the house? Will the design be

easy to build and maintain? Does it

matter?

Look at various homes in the area

you’re looking to build. Compare

the different styles of roofi ng or

cladding and try and visualise how

they might look on the type of

house you have in mind.

Which way’s north? How much sun will the site

get and which way should you orientate your

living and outdoor activities? Do you need to

consider the roof’s aspect to avoid wind/weather

issues?

Which ColorCote® pre-painted metal system should

you use? Your environmental profi le will tell you. What

is the natural environment like? What sort of climatic

conditions? How far from the ocean or harbour?

Prevailing winds? Harsh winters or summers? Any seismic

or geothermal activity nearby? Industrial sites or airports?

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Pacifi c Coilcoaters has an on-going

commitment to sustainability and continuous

product and process improvement. Recent

developments include water-based coating

systems and nil-heavy metal paint systems.

The company has developed processes to

minimise water use with on-site cooling,

recirculation and recycling processes.

Fumes generated during the paint curing

process are reused to fuel the paint curing

ovens, reducing the plant’s overall energy

costs. Excess heat from the drying process is

also used to heat the factory in winter.

All ColorCote® products are coated with

paint systems which are lead and cadmium-

free and suitable for rainwater collection

systems.

All ColorCote® pre-painted steel and

aluminium products are fully recyclable. Any

scraps or old roofi ng material can be recycled

in New Zealand.

Pacifi c Coilcoaters recycles or reuses all its

metal scrap.

Sustainability and Recycling

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Pacifi c Coilcoaters recommends you always use a registered architect or

reputable designer for your roofi ng and cladding designs.

The following links may be helpful:

New Zealand Institute of Architects (NZIA): www.nzia.co.nz

Architectural Designers New Zealand (ADNZ): www.adnz.org

All metal roofi ng and cladding should be installed according to

the Metal Roofi ng Manufacturers’ Code of Practice.

For more details see:

Metal Roofi ng Manufacturers Inc: www.metalroofi ng.org.nz

Roofi ng Association of NZ: www.roofi ngassn.org.nz

For overall building/construction information:

Registered Master Builders’ Federation: www.masterbuilder.co.nz

New Zealand Certifi ed Builders’ Association: www.certifi ed.co.nz

Where to go for more information, ideas or help?

968 Great South Road, PO Box 12 046, Penrose, Auckland.

Telephone: +64 9 579 9199 Facsimile: +64 9 579 7515

© Copyright PCC 2011

www.colorcote.co.nzCOLORCOTE®, ZR8™, ZRX™, ZM8™, ZMX™, AR8™ and ARX™ are Registered Trade Marks of Fletcher Steel Ltd.

Pacifi c Coilcoaters is a trading division of Fletcher Steel Limited a Fletcher Building Limited Business.